WO2024019874A1 - Panneaux structuraux isolés renforcés - Google Patents

Panneaux structuraux isolés renforcés Download PDF

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Publication number
WO2024019874A1
WO2024019874A1 PCT/US2023/026671 US2023026671W WO2024019874A1 WO 2024019874 A1 WO2024019874 A1 WO 2024019874A1 US 2023026671 W US2023026671 W US 2023026671W WO 2024019874 A1 WO2024019874 A1 WO 2024019874A1
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WIPO (PCT)
Prior art keywords
reinforced structural
structural panel
outer layer
reinforcement structures
reinforcement
Prior art date
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PCT/US2023/026671
Other languages
English (en)
Inventor
Jarrett B. Davis
Randal Hoffner
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Ddp Specialty Electronic Materials Us, Llc
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Application filed by Ddp Specialty Electronic Materials Us, Llc filed Critical Ddp Specialty Electronic Materials Us, Llc
Publication of WO2024019874A1 publication Critical patent/WO2024019874A1/fr

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/18—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
    • B32B37/182—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only one or more of the layers being plastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/045—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
    • E04C2/243—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 one at least of the material being insulating
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
    • E04C2/246—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 combinations of materials fully covered by E04C2/16 and E04C2/20
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/73—Hydrophobic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2371/00—Polyethers, e.g. PEEK, i.e. polyether-etherketone; PEK, i.e. polyetherketone
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2375/00—Polyureas; Polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Definitions

  • This disclosure relates generally to reinforced structural panels for use in the field of building construction and building construction materials.
  • Structural insulated sheathing (SIS) panels can be used in standard construction practice. Such panels typically consist of an insulating core and one or more structural layers.
  • the structural layer may be a wood or wood composite material, such as oriented strand (OSB) board, or plywood; cementitious material such as magnesium oxide, or gypsum; steel; aluminum; and fiber-reinforced plastic.
  • OSB oriented strand
  • the use of SIS panels offers many advantages over traditional construction that consists of framing and scaffolding. As such panels are made off-site, assembly is significantly quicker and labor costs are significantly lower; and their use in a wall, roof, or structure helps provide, a more energy-efficient structure.
  • Cladding such as siding or shingles, etc. are typically secured to SIS via fasteners, and it is desirable and that the fasteners adequately secure the cladding to the SIS.
  • the SIS help prevent the withdrawal of the fastener in the final wall or structure, and that the SIS has improved mechanical integrity. It is believed that increased fastening withdrawal properties and shear values of the SIS will allow better performance and new applications for the SIS; for example, use in high-wind zones, heavy weight claddings, or roof attachments.
  • metal strip reinforcements might be used in panels, metal can be subject to corrosion resulting from water ingress into the board, either by damage to the board during construction or from poorly-sealed openings in the boards, and other types of chemical corrosion are possible.
  • a panel particularly an insulated panel suitable for use as structural insulated sheathing (SIS), that is provided with increased fastening withdrawal properties and mechanical integrity when used with cladding without the risk of corrosion.
  • SIS structural insulated sheathing
  • a reinforced structural panel having an insulation layer, an outer layer adjacent a first lateral surface of the insulation layer, and a plurality of reinforcement structures within the reinforced structural panel.
  • the plurality of reinforcement structures are fixed between the insulating layer and the outer layer.
  • the reinforcement structures may be wood or a cementitious material.
  • the reinforced structural panel may further include an additional outer layer on the opposite lateral side of the insulation layer.
  • the additional outer layer may comprise an additional plurality of reinforcement structures fixed between the insulation layer and the additional outer layer.
  • each of the reinforcement structures may be equal in length to the outer layer. Additionally, or alternatively, each of the reinforcement structures may be greater than or equal to one inch wide and less than or equal to twelve inches wide. In some embodiments, each of the reinforcement structures may be greater than or equal to two inches wide and less than or equal to five inches wide. In some embodiments, each of the reinforcement structures may be greater than or equal to two inches wide and less than or equal to three inches wide. In some embodiments, the depth of each of the reinforcement structures is greater than or equal to 0.25 inch and less than or equal to 1.5 inch. Additionally, or alternatively, each of the reinforcement structures has a density equal to the density of the outer layer. In some embodiments, each of the reinforcement structures has a density greater than the density of the outer layer.
  • the external surface of the outer layer may contain markings indicating the location of each of the reinforcement structures. Additionally, or alternatively, the external surface of the outer layer may contain a water-resistant barrier.
  • the outer layer comprises magnesium oxide.
  • the outer layer comprises gypsum. Additionally, or alternatively, the outer layer comprises cementitious board.
  • the outer layer and each of the reinforcement structures comprise magnesium oxide.
  • the insulating layer comprises polyurethane.
  • a method of making reinforced structural panels including adhering a plurality of reinforcement structures, comprised of wood or cementitious material, to a surface of a board and applying an insulating layer to the plurality of reinforcement structures and the surface of the board.
  • the board may be wood, gypsum, magnesium oxide, or cement.
  • the method further includes forming a reinforcement structure.
  • the method further includes applying a second board to the insulating layer.
  • the second board may first be adhered with a plurality of reinforcement structures.
  • the method further includes applying a water- resistant barrier to an outward-facing surface of the board.
  • a method of forming a reinforcement structure is claimed. The method of forming a reinforcement structure including: obtaining a panel of wood or cementitious material; and cutting, from the panel, a strip of the same length as the panel. In some embodiments, the strip is between one and twelve inches wide. Additionally, or alternatively, the strip may between two and four inches wide.
  • the method of forming a reinforcement structure further includes forming the panel.
  • Forming the panel includes: pouring a slurry of uncured cementitious product into a mold and curing the cementitious product.
  • the slurry of uncured cementitious product comprises magnesium oxide and glass fiber.
  • the method of forming a reinforcement structure includes applying an adhesive to the strip.
  • a reinforced structural panel having an insulation layer, an outer layer comprising magnesium oxide adj acent a first lateral surface of the insulation layer, and a plurality of reinforcement structures comprised of magnesium oxide within the reinforced structural panel.
  • the plurality of reinforcement structures are fixed between the insulating layer and the outer layer.
  • a reinforced structural panel having an insulation layer, an outer layer comprising gypsum adjacent a first lateral surface of the insulation layer, and a plurality of reinforcement structures comprised of magnesium oxide within the reinforced structural panel.
  • the plurality of reinforcement structures are fixed between the insulating layer and the outer layer
  • a reinforced structural panel having an insulation layer, an outer layer comprising wood adjacent a first lateral surface of the insulation layer, and a plurality of reinforcement structures comprised of magnesium oxide within the reinforced structural panel.
  • the plurality of reinforcement structures are fixed between the insulating layer and the outer layer.
  • a reinforced structural panel having an insulation layer, an outer layer comprising cementitious board adjacent a first lateral surface of the insulation layer, and a plurality of reinforcement structures comprised of magnesium oxide within the reinforced structural panel.
  • the plurality of reinforcement structures are fixed between the insulating layer and the outer layer.
  • FIG. l is a perspective view of a reinforced structural panel in accordance with an embodiment of the present invention.
  • FIG. 2 is a sectional view of the reinforced structural panel of FIG. 1 taken along site line 2-2 therein.
  • FIG. 3 is a sectional view of a reinforced structural panel in accordance with an embodiment of the present invention.
  • FIG. 4 is a sectional view of a reinforced structural panel in accordance with an embodiment of the present invention.
  • FIG. 5 is a sectional view of a reinforced structural panel in accordance with an embodiment of the present invention.
  • FTG. 6 is a perspective view of a reinforced structural panel in accordance with an embodiment of the present invention.
  • first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
  • Spatially relative terms such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
  • the reinforcement within the panel is designed to improve the strength and mechanical integrity of the outer layer, and therefore the SIS as a whole.
  • the reinforcement measures within the panel allow for commonly accepted engineering design to be utilized for the cladding attachment loads in higher wind zones equivalent to a structural facer while maintaining greater thermal efficiency as the insulation is truly continuous as defined within the IECC (International Energy Conservation Code) as a material that is unbroken except mechanical openings and fasteners. Since the fasteners used to attach the sheathing to the stud will likely be installed through the reinforcement measures, the outer reinforcement measures then become the structural face and maintaining greater than 97% thermal efficiency.
  • This reinforcement strips combined with the outer layer serve to spread the point load of a cladding fastener over the wall panel in a distributed load. This load spreading allows the cladding fastener withdrawal force to increase in a non-linear manner over the traditional methodology of only a single sheet panel, and often times increasing the shear and withdrawal values to double or greater the single sheet values.
  • the wall panel described herein is a reinforced structural panel used as a structural insulated sheathing (SIS) or structural insulated panel (SIP).
  • the reinforced structural panel may include an insulation layer 130, an outer layer 120 and a plurality of reinforcement structures 122, 124, 126, and 128 on an inner surface of the outer layer 120.
  • the reinforcement structures are enclosed or embedded in an insulation layer 130 on the surface of the outer layer 120.
  • the outer layer may comprise magnesium oxide, gypsum, wood, or other cementitious material.
  • Magneium oxide as used herein is meant to include magnesium oxychloride or magnesium oxysulphate or magnesium oxyphosphate or combinations thereof, which can optionally include fdlers (such as perlite, etc.) and other additives such as water resistance and processing additives.
  • the reinforcement structures are narrow strips of wood or cementitious material affixed to the inner surface of the outer layer 120.
  • the panel face can have a surface with a major dimension and a minor dimension.
  • the reinforcement structures are parallel to the major panel dimension, as illustrated by reinforced structural panel 100 in FIG. 1.
  • the reinforcement structures are parallel to the minor panel dimension, as illustrated by reinforced structural panel 200 in FIG. 6.
  • the reinforcement structures are the same length as the major panel dimension.
  • the reinforcement structures are the same length the panel minor panel dimension.
  • the reinforcement structures are spaced evenly along the width of the inner surface of the outer layer. In some embodiments, the reinforcement structures are spaced evenly along the length of the inner surface of the outer layer.
  • the panel is four foot wide
  • the edge of the first reinforcement structure is placed at an edge of the panel and sixteen inches from the edge of the panel the center of the second reinforcement structure is fixed.
  • the center of the third reinforcement structure is fixed sixteen inches from the center of the second reinforcement structure, and the edge of the fourth reinforcement structure is placed at the second edge of the panel, sixteen inches from the center of the third reinforcement structure.
  • the reinforced structural panel may include an additional outer layer 140, as illustrated in the sectional view in FIG. 3. The embodiment illustrated in FIG.
  • the additional outer layer 140 may further include reinforcement structures, as illustrated in the sectional view in FIG. 4.
  • the additional outer layer 140 may have additional reinforcement structures 142, 144, 146, and 148.
  • the reinforcement structures are positioned at the edge of the panel as shown in the sectional views of FIGs. 2-4. Additionally, or alternatively, the reinforcement structures are not positioned at the edge of the panel as shown in the sectional view of FIG. 5.
  • the reinforcement structures may be comprised of wood or cementitious material.
  • cementitious material such as magnesium oxide
  • a fire-retardant outer layer such as an outer layer comprised of magnesium oxide
  • the reinforced structural panel is entirely fire-retardant.
  • the reinforced structural panel may also be configured to be water resistant. Tn some embodiments, the reinforced structural panel may further comprise a water-resistant barrier (WRB). The WRB may be applied to the outward-facing surface of the outer layer of the reinforced structural panel.
  • WRB water-resistant barrier
  • the reinforced structural panel described herein may be manufactured by adhering a plurality of reinforcement structures onto a first surface of a board.
  • the board serves as the outer layer of the reinforced structural panel.
  • the reinforcement structures may be adhered at regular intervals and may be evenly-spaced over the width of the board.
  • the reinforcement structure may be between one inch and twelve inches wide. Additionally, or alternatively, the reinforcement structure may be between one inch and ten inches wide. In some embodiments, the reinforcement structure may be between one inch and eight inches wide. Additionally, or alternatively, the reinforcement structure may be between one inch and six inches wide. In some embodiments, the reinforcement structures are between one inch and four inches wide. Additionally, or alternatively, the reinforcement structures are between two inches and four inches wide. In some embodiments, the reinforcement structure has the same length as the board.
  • the board forming the outer layer, or outer layers may comprise magnesium oxide, gypsum, wood, or cementitious material.
  • cementitious material is meant to include materials containing magnesium oxide as defined herein, or other cement types, such as Portland cement; or any mixtures thereof of these materials.
  • Wood is understood to include oriented strand board (OSB) or other composite materials containing wood products or wood byproducts or plywood.
  • the board forming the outer layer, or outer layers may contain magnesium oxide.
  • the board forming the outer layer, or outer layers may further comprise gypsum. Additionally, or alternatively, the board forming the outer layer, or outer layers may fully comprise gypsum.
  • the outer layer may be a board made of a cementitious material with a glass fiber reinforcing material embedded therein. Additionally, or alternatively, the board may be formed by pouring a slurry of cementitious material with glass fiber reinforcing material into a mold and allowing the cementitious product to cure, or dry.
  • the glass fiber reinforcing material can be in the form of chopped glass fiber. Additionally, or alternatively, the glass fiber reinforcing material may be incorporated into the board in the form of one or more glass fiber scrim(s). Once cured, the board may be removed from the mold prior to adhering the reinforcement structures to the inner surface of the board.
  • an insulating layer is applied over the reinforcement structures and the first surface, or inner surface, of the board.
  • the insulating layer serves as the primary mechanism for holding the reinforcement structures in place.
  • the insulation layer is injected at a high pressure, therefore the use of an adhesive to apply the strips to the board may be required to prevent the reinforcement structures from dislodging and “floating” during the application of the insulation layer.
  • the insulating layer may be between one inch and three inches thick or greater depending on the application. In some embodiments, the insulating layer is two inches thick. In some embodiments, the insulating layer comprises polyurethane or polyester. In some embodiments, the insulating layer may comprise polystyrene. Examples of polystyrene insulation include expanded polystyrene foam and extruded polystyrene foam. Additionally, or alternatively, the insulating layer may comprise a polyisocyanurate, polyurea, phenolic foam or an organic aerogel.
  • the insulating layer may comprise an inorganic insulating material, such as mineral wool, glass wool, compressed fumed silica, perlite, calcium silicate, foamed glass or silica aerogel blanket.
  • the insulating layer can be a machined, pre-made foam containing slots of a suitable size for surrounding and affixing the reinforcement structures to the outer layer.
  • the insulating layer may comprise mineral wool.
  • the insulating layer may be a rigid pour foam or injected formed from a two-part Class I rated urethane.
  • a second board may be applied.
  • the second board is applied after the application of the insulation layer.
  • the second board is applied prior to the application of the insulation layer, and the insulation layer is applied between the two boards.
  • an additional plurality of reinforcement structures is adhered to the second board in the manner previously described.
  • the reinforcement structures may be formed by obtaining a panel of wood or cementitious material.
  • the panel may be the same board of the outer layer of the reinforced structural panel. In other embodiments, the panel may be different from the board of the outer layer of the reinforced structural panel.
  • the method continues with cutting, from the panel, a strip.
  • the strip may be the same length as of either the major surface dimension or the minor surface dimension of the panel as previously described herein.
  • the strip may have a width between one inch and twelve inches. In some embodiments, the strip may have a width between one inch and ten inches. Tn some embodiments, the strip may have a width between one inch and eight inches. In some embodiments, the strip may have a width between one inch and six inches.
  • the strip may have a width between one inch and four inches. Additionally, or alternatively, the strip may have a width between two inches and five inches. Additionally, or alternatively, the strip may have a width between two inches and three inches.
  • the depth of the reinforcement structure is determined by the panel that the strip is cut from. In some embodiments, the reinforcement structure has a depth of about 0.25 inch to about 1.5 inch. Additionally, or alternatively, the reinforcement structure is about 0.5 inch in depth.
  • the panel is cut from a composite cementitious panel.
  • the composite cementitious panel may be made from a slurry of uncured cementitious material, such as magnesium oxide, with a glass fiber reinforcing material embedded therein. The slurry may be poured into a mold and cured, or dried. Once cured, the panel may be removed from the mold.
  • the composite cementitious panel may be about 0.25 inch to about 1.5 inch thick. In some embodiments the composite cementitious panel is about 0.5 inch thick.
  • a water-resistant barrier may be applied to an external surface of the outer layer.
  • the WRB may be any commercially available WRB known in the art.
  • the WRB may be a liquid applied to the surface via spraying, painting, or coating. Additionally, or alternatively, the WRB may be a sheet that is adhered to the surface.
  • WRB sheets meet the requirements of building codes, such as ASTM E2556, Standard Specification for a WRB. This code requires a dry tensile strength (both machine direction and cross direction (MD/CD)) per ASTM D828 of at least 20 pounds force per inch, and a water resistance, per AATCC 127 (held at 55 cm), of no leakage in 5 hours.
  • Useful WRB sheets are generally any sheet material that does not allow or restricts movement of liquid water through the sheet but does allow some movement through the sheet of vapor, particularly water vapor.
  • the WRB sheet is polymeric. Preferred polymeric sheets are polyethylene (PE) or polypropylene (PP).
  • WRB sheet is a nonwoven fibrous web of flash-spun plexifilamentary high-density PE (HDPE) fibers available from DuPont, Wilmington, DE sold under the tradename Tyvek® HomewrapTM or Tyvek® CommercialWrap.
  • a suitable polypropylene substrate is available under the tradename Typar® Building Wraps.
  • the WRB is a coating on the outer layer, the coating is preferably a polymeric coating having a vapor permeability that is greater than the vapor permeability of the insulating layer, as determined in accordance with ASTM E96/E96M-22.
  • the coating comprises a polymer made with either an acrylate monomer, a styrene monomer, or some combination thereof.
  • reinforced boards were made and tested per ASTM D1761- 20, Standard Test Methods for Mechanical Fasteners in Wood, with variances from method being the crosshead speed was 0.5’7minute.
  • Concealer® #10-9x 1-5/8” screw fasteners were obtained from the manufacturer and tested as received.
  • Reinforcement structures in the form of strips having a width of 4.5” were cut from one 4’ x 8’ board made of magnesium oxide board having an embedded fiberglass scrim. The strips were then used to make structural insulated sheathing (SIS) comprising an outer layer of board made of magnesium oxide board having an embedded fiberglass scrim, the strips adjacent and spaced apart on the outer layer, and a foam holding the strips in place.
  • SIS structural insulated sheathing
  • the final SIS had a thickness of 2.75”.
  • fasteners were then screwed into the outer board and also into and through the adjacent strips.
  • fasteners were only screwed into the outer board and into the foam, missing the strips of reinforcement.
  • the screws were not screwed flush to the surface of the outer layer, but to a depth that left a portion of the fastener exposed exterior to the outer layer for a testing fixture to grab the fastener.
  • the fasteners were then removed from the SIS using on a Shimadzu AGS-X lOkN Universal Test Machine (Part Number 337-01261-21) operating a 10,000 Newton load cell (Model SSM-DAL-10KN) at a crosshead speed of 0.5 in. /min. All conditioning of the test specimens and test conditions were at the standard laboratory conditions of 72°F ⁇ 5.0°F and 50% ⁇ 10% relative humidity.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Building Environments (AREA)

Abstract

L'invention concerne un panneau structural renforcé et un procédé de fabrication dudit panneau structural renforcé. Ledit panneau structural renforcé comprend une couche isolante (130), une couche externe (120) adjacente à une première surface latérale de la couche isolante, et une pluralité de structures de renforcement (122, 124, 126, 128) fixées entre la couche isolante et la couche externe. Les structures de renforcement peuvent être du bois ou un matériau cimentier, tel que de l'oxyde de magnésium. La couche externe du panneau structural renforcé peut être n'importe quel panneau en bois ou panneau cimentier, tel que l'oxyde de magnésium ou le gypse. La pluralité de structures de renforcement peuvent s'étendre parallèlement à la longueur ou à la largeur du panneau structural. La pluralité de structures de renforcement peuvent être fixées, au moins partiellement, à la couche externe à l'aide d'un adhésif.
PCT/US2023/026671 2022-07-18 2023-06-30 Panneaux structuraux isolés renforcés WO2024019874A1 (fr)

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US202263389968P 2022-07-18 2022-07-18
US63/389,968 2022-07-18

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6308491B1 (en) * 1999-10-08 2001-10-30 William H. Porter Structural insulated panel
US6408594B1 (en) * 1999-06-16 2002-06-25 William H. Porter Reinforced structural insulated panels with plastic impregnated paper facings
US20170101776A1 (en) * 2015-10-13 2017-04-13 Ronald White Building insulations, building insulation systems and related methods
FR3048441A1 (fr) * 2016-03-07 2017-09-08 Art Metal Charpente Paroi composite pour la construction d'un batiment, ainsi qu'ensemble de construction d'un batiment comportant une telle paroi composite
US20210252543A1 (en) * 2020-02-13 2021-08-19 Covestro Llc Methods and systems for manufacturing foam wall structures

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6408594B1 (en) * 1999-06-16 2002-06-25 William H. Porter Reinforced structural insulated panels with plastic impregnated paper facings
US6308491B1 (en) * 1999-10-08 2001-10-30 William H. Porter Structural insulated panel
US20170101776A1 (en) * 2015-10-13 2017-04-13 Ronald White Building insulations, building insulation systems and related methods
FR3048441A1 (fr) * 2016-03-07 2017-09-08 Art Metal Charpente Paroi composite pour la construction d'un batiment, ainsi qu'ensemble de construction d'un batiment comportant une telle paroi composite
US20210252543A1 (en) * 2020-02-13 2021-08-19 Covestro Llc Methods and systems for manufacturing foam wall structures

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